Systems and methods for forming and using an adhesive tape

ABSTRACT

Systems and methods are described for manufacturing an adhesive tape. An example method includes: providing a plurality of adhesive webs, wherein each web includes a hot melt adhesive adhered to a backing material; providing a fabric web having a fabric material; guiding a first adhesive web from the plurality of adhesive webs into a first position proximate a first side of the fabric web; guiding a second adhesive web from the plurality of adhesive webs into a second position proximate a second side of the fabric web; applying heat and pressure to form a web of the baffle tape in which the first adhesive web is bonded to the first side of the fabric web and the second adhesive web is bonded to the second side of the fabric web; and rewinding the web of the baffle tape into a roll.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional PatentApplication No. 62/559,817, filed Sep. 18, 2017, the entire contents ofwhich are incorporated by reference herein.

TECHNICAL FIELD

In various embodiments, the invention relates to adhesive materials and,more particularly, to systems and methods for manufacturing and using anadhesive tape.

BACKGROUND

Hot melt adhesives (HMAs), such as thermoplastic polyurethanes (TPUs),are commonly used to form bonds between two or more substrates, such asfabrics, foams, plastics, and other composites and combinations. HMAscan exhibit high tensile strength, excellent flexibility and goodabrasion resistance. HMA films can be used with a variety ofmanufacturing methods, ranging from hot-melt to flame lamination.Various welding operations, including ultrasonic, HF, RF and platensealing, can be used to activate these films. HMAs can be used to formseams between fabric materials in garment manufacturing processes.

Insulated panels for use in outerwear, sleeping bags, and similararticles generally include a loose insulating material (e.g., downfeathers) confined within chambers formed between inner and outer fabriclayers. The chambers are typically formed by stitching or bonding theinner and outer fabric layers together to define edges of the chambers.

There is a need for improved systems and methods for manufacturingadhesive materials and using the adhesive materials to manufactureinsulated panels.

SUMMARY OF THE INVENTION

Embodiments of the systems and methods described herein relate to themanufacture and use of an adhesive tape. In preferred examples, theadhesive tape is manufactured using a continuous web process in whichwebs of adhesive are guided into position relative to a fabric web andbonded to the fabric web in one or more laminators. The resultingadhesive tape can be used to manufacture insulated panels for use inouterwear, sleeping bags, and similar articles.

In general, in one aspect, the subject matter of this disclosure relatesto a method of manufacturing a baffle tape. The method includes:providing a plurality of adhesive webs, each adhesive web including ahot melt adhesive adhered to a backing material; providing a fabric webthat includes a fabric material; guiding a first adhesive web from theplurality of adhesive webs into a first position proximate a first sideof the fabric web; guiding a second adhesive web from the plurality ofadhesive webs into a second position proximate a second side of thefabric web; applying heat and pressure to form a web of the baffle tapehaving the first adhesive web bonded to the first side of the fabric weband the second adhesive web bonded to the second side of the fabric web;and rewinding the web of the baffle tape into a roll.

In certain examples, providing the plurality of adhesive webs includesunwinding at least one roll of adhesive material having the hot meltadhesive adhered to the backing material. Providing the plurality ofadhesive webs can include slitting an initial adhesive web into theplurality adhesive webs. Providing the fabric web can include unwindinga roll of the fabric material. Providing the fabric web can includeslitting an initial fabric web into a plurality of fabric webs includingthe fabric web. In some implementations, guiding the first adhesive webincludes directing the first adhesive web into a first lateral location,and guiding the second adhesive web includes directing the secondadhesive web into a second lateral location different from the firstlateral location. Alternatively or additionally, guiding the firstadhesive web can include flipping the first adhesive web, such that thehot melt adhesive of the first adhesive web is positioned between thefabric web and the backing material of the first adhesive web. Thebaffle tape can include the first adhesive web positioned proximate anedge of the fabric web and the second adhesive web positioned proximatean opposite edge of the fabric web. The applying step can includepassing the first adhesive web, the fabric web, and the second adhesiveweb through a nip of a belt lamination machine.

In some examples, the method can include: cutting the baffle tape into aplurality of adhesive strips; placing the plurality of adhesive stripsin a predetermined arrangement between a first fabric sheet and a secondfabric sheet; applying heat and pressure to (i) bond the plurality ofadhesive strips to the first fabric sheet and the second fabric sheetand (ii) form a plurality of baffles connecting the first fabric sheetand the second fabric sheet, wherein each baffle includes a non-bondedportion of one of the plurality of adhesive strips. The predeterminedarrangement can include the plurality of adhesive strips in asubstantially parallel and spaced-apart arrangement. Each adhesive stripfrom the plurality of adhesive strips can include a Z-shaped crosssection.

In certain instances, the first and second fabric sheets and twoadjacent baffles define an insulation chamber. The method can includefilling the insulation chamber with an insulating material. The methodcan include removing the backing material from the plurality of adhesivestrips prior to placing the plurality of adhesive strips in thepredetermined arrangement. The method can be used to manufacture thebaffle tape and/or the insulated panel.

In another aspect, the subject matter of this disclosure relates to asystem for manufacturing a baffle tape. The system includes: a pluralityof adhesive webs including a hot melt adhesive adhered to a backingmaterial; a fabric web including a fabric material; a plurality ofrollers for (i) guiding a first adhesive web from the plurality ofadhesive webs into a first position proximate a first side of the fabricweb and (ii) guiding a second adhesive web from the plurality ofadhesive webs into a second position proximate a second side of thefabric web; at least one laminator for applying heat and pressure toform a web of the baffle tape including the first adhesive web bonded tothe first side of the fabric web and the second adhesive web bonded tothe second side of the fabric web; and a rewinder for rewinding the webof the baffle tape into a roll.

In some examples, the system includes at least one roll of adhesivematerial for providing the plurality of adhesive webs. The system caninclude a slitter for slitting an initial adhesive web into theplurality of adhesive webs. Alternatively or additionally, the systemcan include at least one roll of fabric for providing the fabric web.The system can include a slitter for slitting an initial fabric web intoa plurality of fabric webs including the fabric web.

In certain instances, the plurality of rollers can be configured to (i)direct the first adhesive web into a first lateral location and (ii)direct the second adhesive web into a second lateral location differentfrom the first lateral location. The plurality of rollers can beconfigured to flip the first adhesive web, such that the hot meltadhesive of the first adhesive web is positioned between the fabric weband the backing material of the first adhesive web. The baffle tape caninclude the first adhesive web positioned proximate an edge of thefabric web and the second adhesive web positioned proximate an oppositeedge of the fabric web. The at least one laminator can be or include abelt lamination machine.

These and other objects, along with advantages and features ofembodiments of the present invention herein disclosed, will become moreapparent through reference to the following description, the figures,and the claims. Furthermore, it is to be understood that the features ofthe various embodiments described herein are not mutually exclusive andcan exist in various combinations and permutations.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings, like reference characters generally refer to the sameparts throughout the different views. Also, the drawings are notnecessarily to scale, emphasis instead generally being placed uponillustrating the principles of the invention. In the followingdescription, various embodiments of the present invention are describedwith reference to the following drawings, in which:

FIG. 1 is a schematic, end view of an adhesive tape that includes afabric material and two strips of adhesive, in accordance with certainembodiments of the invention.

FIG. 2 is a schematic, top view of the adhesive tape of FIG. 1, inaccordance with certain embodiments of the invention.

FIG. 3 includes a schematic, side view of a process for manufacturing anadhesive tape, in accordance with certain embodiments of the invention.

FIG. 4 is a schematic, end view of a fabric web and multiple strips ofadhesive, in accordance with certain embodiments of the invention.

FIG. 5 is a schematic, side view of a rewinder used in a process formanufacturing an adhesive ape, in accordance with certain embodiments ofthe invention.

FIG. 6 is a perspective photograph of a roll of an adhesive tape, inaccordance with certain embodiments of the invention.

FIG. 7 includes a schematic, side view of a process for manufacturing anadhesive tape, in accordance with certain embodiments of the invention.

FIG. 8 is a flowchart of a method of manufacturing an adhesive tape, inaccordance with certain embodiments of the invention.

FIG. 9 is a schematic, top view of a plurality of strips of adhesivetape on a sheet of fabric, in accordance with certain embodiments of theinvention.

FIG. 10 is a schematic, end view of an insulated panel formed using anadhesive tape, in accordance with certain embodiments of the invention.

FIG. 11 is a flowchart of a method of manufacturing an insulated panelusing an adhesive tape, in accordance with certain embodiments of theinvention.

FIG. 12 includes a schematic, side view of a process for manufacturingan adhesive tape, in accordance with certain embodiments of theinvention.

DETAILED DESCRIPTION

It is contemplated that apparatus, systems, methods, and processes ofthe claimed invention encompass variations and adaptations developedusing information from the embodiments described herein. Adaptationand/or modification of the apparatus, systems, methods, and processesdescribed herein may be performed by those of ordinary skill in therelevant art.

It should be understood that the order of steps or order for performingcertain actions is immaterial so long as the invention remains operable.Moreover, two or more steps or actions may be conducted simultaneously.

Examples of the systems and methods described herein can be used tomanufacture an adhesive tape material that includes a strip of fabriccoated with top and bottom strips of adhesive. The adhesive tape can beused to manufacture insulated panels for use in outerwear, sleepingbags, and similar applications. In certain examples, the adhesive tapeis referred to herein as “baffle tape.”

Referring to FIG. 1, in certain examples, an adhesive tape 10 includes astrip of fabric 12, a top strip of adhesive 14, and a bottom strip ofadhesive 16. The top strip 14 of adhesive is positioned near one edge 18of the strip of fabric 12 and covered with a release paper or backingmaterial 20. The bottom strip of adhesive 16 is positioned along anopposite edge 22 of the strip of fabric and is covered with the backingmaterial 20. A thickness T1 of the top strip of adhesive 14 and/or thebottom strip of adhesive 16 can be, for example, from about 1 mil (2.5μm) to about 8 mils (about 200 μm) or preferably from about 2 mils (50μm) to about 6 mils (150 μm). Example thicknesses for the adhesive tapecomponents are presented in Table 1.

TABLE 1 Exemplary thickness parameters for adhesive tape. Parameter Min.Typical Max. T1, thickness of adhesive strip (μm) 25 100 200 T2,thickness of fabric (μm) 50 150 250 T3, thickness of backing material(μm) 25 100 150

Referring to FIG. 2, in some examples, the adhesive tape 10 includesuncoated outer portions of fabric 24 and 26, a top adhesive portion 28(corresponding to the top strip of adhesive 14), a bottom adhesiveportion 30 (corresponding to the bottom strip of adhesive 16), and acentral uncoated portion of fabric 32. A width W1 of the top strip ofadhesive 14 and/or the bottom strip of adhesive 16 can be, for example,from about 2 mm to about 25 mm, preferably from about 4 mm to about 10mm, or most preferably from about 4 mm to about 6 mm. Example widths foreach portion of the adhesive tape 10 are presented in Table 2. In someinstances, approximately 30% of each side of the strip of fabric 12 iscovered with adhesive.

TABLE 2 Exemplary width parameters for adhesive tape. Parameter Min.Typical Max. W1, width of adhesive strip (mm) 2 5 25 W2, width ofcentral uncoated fabric 2 10 60 portion (mm) W3, width of outer uncoatedfabric 0 1 2 portion (mm) W4, width of adhesive tape (mm) 6 22 114

In various implementations, the strip of fabric 12 is or includes asynthetic or natural woven or non-woven fabric material. Additionally oralternatively, the strip of fabric 12 can have a weft stretch componentthat permits the strip of fabric 12 to be stretched, for example, byabout 5%, about 10%, about 20%, from about 5% to about 20%, or fromabout 5% to about 80%. The fabric material can be or include a meshfabric, which can have holes that range in diameter from about 1 mil (25μm) to about 30 mils (760 μm) and/or can have an average diameter ofabout 15 mils (380 μm). A minimum air permeability of the fabricmaterial can be about 0.5 cfm or from about 0.5 cfm to about 43 cfm, asmeasured by FRAZIER air permeability, for example, using FRAZIER machinenumber 5348 manufactured by FRAZIER PRECISION INSTRUMENT CO., Inc.FRAZIER air permeability measurements are generally performed byapplying a vacuum to a fabric sample and measuring a flowrate of airthat passes through sample.

In certain examples, the top and bottom adhesive strips 14 and 16 can beor include an adhesive material, such as one or more thermoplastic orthermoset adhesives. The adhesive material can be or include, forexample, one or more polyurethanes, polyesters, polyamides, polyolefins,or any blend thereof. Thermal properties of the adhesive material caninclude, for example, thermomechanical analysis (TMA) onset points in arange from about 50° C. to about 160° C., preferably in a range fromabout 50° C. to about 90° C., and most preferably in a range from about50° C. to about 70° C. The top and bottom adhesive strips 14 and 16preferably bond to the strip of fabric 12 with an average peel strengthof at least 3 lb/in, as measured in a T-peel test in which a rate ofextension is 300 mm/min and a sample temperature is 18-22° C., orpreferably 20° C. (see ASTM D1876-01).

The top and bottom adhesive strips 14 and 16 can be formed initially onthe backing material 20 by extrusion, solvent coating, or aqueouscoating. The backing material 20 can be or include a paper or polymericmaterial and/or can have a coating of non-stick or low surface energymaterial such as, for example, polytetrafluoroethylene (PTFE) orsilicone.

FIG. 3 is a schematic side view of an example process 50 formanufacturing the adhesive tape 10. An adhesive web 52 is provided froman adhesive roll 54 and includes a backing material (e.g., the backingmaterial 20) coated with a bottom layer of adhesive material (e.g., theadhesive material included in the top and bottom adhesive strips 14 and16). The adhesive web 52 is guided by a plurality of rollers 56 and slitinto a plurality of adhesive webs 58 by a slitter 59, which can include,for example, a knife, a rotary blade, a rotary die cutter, and/or ashear knife blade assembly. The plurality of adhesive webs 58 arewrapped around a tension roller 60 for controlling and/or measuring webtension. The tension roller 60 may include or be in communication with atension sensor that measures web tension. The plurality of adhesive webs58 are guided through a nip formed by a pair of rubber rollers 62 thatpull the adhesive webs 58 and maintain a desired web velocity. Afterpassing through a pair of rubber guide rollers 64, one or more bottomadhesive webs 66 from the plurality adhesive webs 58 diverge from one ormore top adhesive webs 68 from the plurality of adhesive webs 58. Forexample, every other web from the plurality of adhesive webs 58 can bediverted to form the bottom adhesive webs 66 and the remaining webs canbe diverted to form the top adhesive webs 68. In one implementation,there are 52 adhesive webs 58, 26 bottom adhesive webs 66, and 26 topadhesive webs 68, though other numbers of webs can be used. Additionaltension rollers 70 and 72 (e.g., with tension sensors) are provided forcontrolling and/or measuring tension in the one or more bottom adhesivewebs 66 and the one or more top adhesive webs 68, respectively. Each ofthe one or more bottom adhesive webs 66 is preferably flipped over at atwist location 74, for example, by twisting each bottom adhesive web 66.At this point, the adhesive material is on a top side of the one or morebottom adhesive webs 66 and on a bottom side of the one or more topadhesive webs 68.

A fabric web 76 is provided from a fabric roll 78 and guided intoposition between the one or more bottom adhesive webs 66 and the one ormore top adhesive webs 68. As shown in a magnified view 80, a pluralityof sensors 82 and 84 (e.g., optical sensors and/or tension sensors) areused to monitor the one or more bottom adhesive webs 66 and the one ormore top adhesive webs 68, for example, to ensure webs are properlypositioned and remain intact. If the plurality of sensors 82 and 84detects a broken web, for example, the process 50 can be stopped (e.g.,automatically) so that the broken web can be repaired. As shown in asecond magnified view 86, a fabric slitter 88 (e.g., an ultrasonicslitter) is used to slit the fabric web 76 into a plurality of separatefabric webs 90. For example, referring to FIG. 4, the fabric web 76 canbe slit by the fabric slitter 88 at three or more slit locations 92 toform four or more separate fabric webs 90. Each separate fabric web 90can be associated with a top adhesive web 68 positioned along one edgeof the separate fabric web 90 and a bottom adhesive web 66 positionedalong an opposite edge of the separate fabric web 90. One or more webguiding devices, including steering rollers, profiled rollers, groovedrollers, and/or one or more alignment guides (e.g., positioned near thefabric slitter 88), can be used to guide each top and bottom adhesiveweb 66 and 68 into a desired position (e.g., a lateral position and/or aseparation distance) relative to the fabric web 76 and/or the separatefabric webs 90.

Referring again to FIG. 3, after the separate fabric webs 90, the bottomadhesive webs 66, and the top adhesive webs 68 have been guided intodesired relative positions, the webs are passed through one or morelaminators 94 that apply heat and pressure to bond the bottom and topadhesive webs 66 and 68 to the separate fabric webs 90. The one or morelaminators 94 can be or include, for example, a heated belt laminator,such as Model No. HP600LF, manufactured by HASHIMA Co. Ltd, though otherlaminators can be used. In some examples, the one or more laminators 94include a first laminator for bonding the top adhesive webs 68 to theseparate fabric webs 90 and a second laminator for bonding the bottomadhesive webs 66 to the separate fabric webs 90.

At an exit of the one or more laminators 94, a plurality of webs ofadhesive tape 10 are wrapped around a series of festoon rollers 96 andfed into a rewinder 98 (e.g., a differential rewinder) where the webs ofadhesive tape 10 are wound into rolls 100 on a first set of spools 102.When the first set of spools 102 reaches a desired size, the webs ofadhesive tape 10 can be cut and moved to a second set of spools 104.

Referring to FIG. 5, while the webs of adhesive tape 10 are being movedto the second set of spools, and/or as the second set of spools 104 arebeing accelerated to web speed, the series of festoon rollers 96 can betranslated apart from one another to store extra web material that thesecond set of spools 104 is unable to receive. For example, every otherroller among the festoon rollers 96 can translate in an upward direction106 while the remaining festoon rollers 96 translate in a downwarddirection 108. This increases a length of a web path and allows webmaterial to accumulate between the festoon rollers 96. Once the webs ofadhesive tape 10 are transferred to the second set of spools 104 (e.g.,using a pressure-sensitive adhesive), and/or the second set of spools104 has reached a desired rewind speed, the festoon rollers 96 cantranslate back to initial locations, as shown in FIG. 3, and any extraweb stored between the festoon rollers 96 can be wound onto the secondset of spools 104.

FIG. 6 includes a photograph of an example roll 100 of adhesive tape 10that can be made using the process 50. A strip of the adhesive tape 10can be unwound from the roll 100 and cut to a desired length.

Referring again to FIG. 3, in various alternative examples, the slitter59 is not used and the plurality of adhesive webs 58 can be obtainedfrom a plurality of adhesive rolls 54. Additionally or alternatively,use of the fabric slitter 88 can be avoided by providing the separatefabric webs 90 from a plurality of fabric rolls 78. In some instances,the fabric slitter 88 can be positioned after the one or more laminators94 to slit the fabric web 76 after the top and bottom adhesive webs 66and 68 have been bonded to the fabric web 76. Additionally oralternatively, one or more rolls 100 of the adhesive tape 10 can be cutinto multiple rolls 100.

As the process 50 continues and the sources for the adhesive web 52and/or the fabric web 76 are reduced, the adhesive roll 54 and/or thefabric roll 78 may need to be replaced, for example, using a splicingprocedure. In preferred implementations, an old roll can be replacedwith a new roll by splicing a new web from the new roll onto an old webfrom the old roll. Once the new web is attached to the old web, the oldweb can be cut and the old roll can be removed. The splicing procedureis preferably performed without stopping the process 50.

FIG. 7 is a schematic side view of an alternative process 120 formanufacturing the adhesive tape 10. The alternative process 120 utilizesa rewinder 122 in which one or more first webs 124 of adhesive tape 10are wound onto a first roll 126 on a first spool 128 and one or moresecond webs 130 of adhesive tape 10 are wound simultaneously onto asecond roll 132 on a second spool 134. When the first and second rolls126 and 132 reach a desired size, the process 120 can be stopped and thefirst and second webs 124 and 130 can be cut, to allow the first andsecond rolls 126 and 132 to be removed. New rolls can be created byattaching the cut first and second webs 124 and 130 to the first andsecond spools 128 and 134, respectively, and restarting the process 120.

Referring to a separate front view 136 in FIG. 7, in some examples, therubber guide rollers 64 include a top guide roller 138 and a bottomguide roller 140 that are profiled or grooved to guide the one or moretop adhesive webs 68 and the one or more bottom adhesive webs 66. Theprofile of each roll can include an outer diameter that oscillates alonga length of the roll between a minimum value and a maximum value. Theoscillation can be or approximate, for example, a square wave or a sinewave. In the depicted example, the profiles of the top and bottom guiderollers 138 and 140 can be meshed together, such that the diameter ofone roller is generally at the maximum value in lateral locations wherethe diameter of the other roller is at the minimum value. The topadhesive webs 68 are preferably wrapped around portions of the top guideroller 138 in lateral locations where the diameter of the top guideroller 138 is at the maximum value. The bottom adhesive webs 66 arepreferably wrapped around portions of the bottom guide roller 140 inlateral locations where the diameter of the bottom guide roller 140 isat the maximum value.

FIG. 8 is a flowchart of an example method 150 of manufacturing anadhesive tape (e.g., the adhesive tape 10). A plurality of adhesive websare provided (step 152) that include an adhesive material (e.g., a hotmelt adhesive) adhered to a backing material. A fabric web is provided(step 154) that includes a fabric material. A first adhesive web fromthe plurality of adhesive webs is guided (step 156) into a firstposition proximate a first side of the fabric web. A second adhesive webfrom the plurality of adhesive webs is guided (step 158) into a secondposition proximate a second side of the fabric web. Heat and pressureare applied (step 160) to form a web of the adhesive tape (also referredto as baffle tape) having the first adhesive web bonded to the firstside of the fabric web and the second adhesive web bonded to the secondside of the fabric web. The web of the adhesive tape is wound (step 162)into a roll.

Referring to FIGS. 9 and 10, in certain examples, the adhesive tape 10can be used to form an insulated panel 200 for use in outerwear (e.g.,down jackets), sleeping bags, and similar articles. The insulated panel200 can be formed by cutting the adhesive tape 10 into a plurality ofstrips 202 and placing the strips 202 onto a bottom sheet of fabric 204.As depicted in FIG. 9, the strips 202 can be arranged to be parallel toone another and evenly spaced, though other arrangements may bedesirable. For example, one or more of the strips 202 could besubstantially perpendicular to another strip (or placed at other angles,e.g., 45 degrees) and/or could overlap with one or more other strips202. The depicted example shows the strips 202 of adhesive tape 10 beingpositioned with the top strip of adhesive 14 facing away from the bottomsheet of fabric 204 and the bottom strip of adhesive 16 (not shown)facing toward the bottom sheet of fabric 204. Any backing material(e.g., backing material 20) is preferably removed from the strips 202prior to placing the strips 202 on the bottom sheet of fabric 204.

Referring to FIG. 10, with the strips 202 of adhesive tape 10 in thedesired arrangement, a top sheet of fabric 206 can be positioned on topof the bottom sheet of fabric 204, such that the strips 202 are betweenthe bottom sheet of fabric 204 and the top sheet of fabric 206. Heat andpressure can then be applied (e.g., in a laminator or heat press) tobond the top strip of adhesive 14 to the top sheet of fabric 206 and thebottom strip of adhesive 16 to the bottom sheet of fabric 204. Thebonding process forms a plurality of seams 208 that define edges ofchambers 210 between the bottom and top sheets of fabric 204 and 206.The chambers 210 can be filled with an insulating material, such as downfeathers, loose synthetic insulation, or synthetic batting. A non-bondedportion of the adhesive tape 10 (e.g., the central uncoated portion offabric 32) connects the bottom and top sheets of fabric 204 and 206 ineach seam 208 and serves as a baffle 212 that prevents insulatingmaterial from moving between adjacent chambers 210. The bottom and topsheets of fabric 204 and 206 can be or include, for example, low denier(e.g., 10D) polyester or nylon fabric for use in lightweight downjackets or coated outerwear fabric for use in heavier weight downjackets.

FIG. 11 is a flowchart of an example method 250 of manufacturing aninsulated panel (e.g., the insulated panel 200) using an adhesive tape(e.g., the adhesive tape 10). The adhesive tape is cut (step 252) into aplurality of adhesive strips. The plurality of adhesive strips areplaced (step 254) in a predetermined arrangement between a first fabricsheet and a second fabric sheet. Heat and pressure are applied (step256) to (i) bond the plurality of adhesive strips to the first fabricsheet and the second fabric sheet and (ii) form a plurality of bafflesconnecting the first fabric sheet and the second fabric sheet. Each ofthe baffles is or includes a non-bonded portion of one of the pluralityof adhesive strips. The first and second fabric sheets and two adjacentbaffles define an insulation chamber that is filled (step 258) with aninsulating material.

Compared to previous seam designs, which are typically formed bystitching top and bottom sheets of fabric together, the seams 208 formedusing the adhesive tape 10 provide several advantages. For example, thefabric material of the adhesive tape 10 is designed to be permeable,such that air can flow easily through the baffles 212, from one chamber210 to another. This helps prevent sudden over pressurizing and/orrupture of any one chamber 210 and reduces a likelihood that insulatingmaterials (e.g., down feathers) will poke out of or pass through thebottom sheet of fabric 204 and/or the top sheet of fabric 206. Airpermeability at the baffles 212 can also make it easier to compress theinsulating panel 200, such that down jackets, sleeping bags, or otherarticles that include the insulating panel 200 can be more easilyreduced in size, for example, for storage in a suitcase or othercontainer. Additionally, the fabric material of the adhesive tape 10 ispreferably stretchable, for example, in a weft or cross-direction. Thestretchable nature of the fabric material can make the seams 208 moredurable and able to withstand greater stresses and/or more wear andtear. Another advantage is that the seams 208 are generally warmer thanconventional seams formed by stitching. For example, unlike conventionalseams, which are thin and generally unable to accommodate insulatingmaterials, the seams 208 produced with the adhesive tape 10 aregenerally thicker (e.g., due to the baffles 212) and able to accommodateat least some of the insulating materials. This results in warmer seamregions and reduces the need to compensate for cold seams by making thechambers 210 thicker. Accordingly, jackets, sleeping bags, and otheritems that include the insulating panel 200 can have thinner chambers210 and/or can use less insulating material, compared to conventionalpanels, to achieve a desired warmth or thermal resistance. Further, byeliminating the need for stitching, the seams 208 can be produced withno stitching holes, which can be a source of heat loss or waterpenetration and/or can permit insulating materials to protrude or passthrough fabric layers.

FIG. 12 is a schematic side view of an alternative process 300 formanufacturing the adhesive tape 10. The alternative process 300 utilizesone or more cooling plates 302 that cool the adhesive web 52 to adesired temperature (e.g., at or below room temperature) prior to beingslit by the slitter 59. The cooling plates 302 can help keep theadhesive material in a solid state during the slitting process and/orsubsequent steps. Webs of edge trim material 302 created by the slitter59 are wound onto a pair of edge trim rewinder rolls 304. A dancer rollassembly 308 or similar device is used to adjust and/or control tensionor web speed in the one or more bottom adhesive webs 66 and the one ormore top adhesive webs 68. Web guides 309 (e.g., guide bars) can be usedto guide the bottom and top adhesive webs 66 and 68 to desired laterallocations (e.g., in a cross-web direction). The web guides 309 caninclude, for example, alignment slots or channels that control or definea lateral position of each individual web. Tension sensors 310 can beused to provide, monitor, and/or control tension in the bottom and topadhesive webs 66 and 68. In some instances, for example, the tensionsensors 310 can provide tension (e.g., using one or more springs oractuators) to individual bottom and top adhesive webs 66 and 68 and/orprovide a machine operator with a visual indication of a tension settingin each web. Additionally or alternatively, optical sensors 312 can beused to guide and/or detect breakage of the bottom and top adhesive webs66 and 68. As in the process 50, described above, the bottom adhesivewebs 66 can be flipped over at the twist location 74.

In the depicted example, the fabric web 76 is slit using an ultrasonicslitter 314 or similar device prior to being guided into positionrelative to the bottom and top adhesive webs 66 and 68. After passingthrough the laminator 94, the adhesive tape 10 is wound onto the firstand second rolls 126 and 132, as described above for the process 120.

In preferred implementations, the process 300 can be controlled usingsignals from a collection of process sensors, including the tensionsensors 310 and/or the optical sensors 312. When one of the bottomadhesive webs 66 or the top adhesive webs 68 breaks or becomes jammed,for example, the tension sensors 310 may detect a sudden drop in webtension and/or the optical sensors 312 may no longer detect the presenceof a web. In such an instance, a control system can automatically stopthe process 300 and/or can alert a machine operator to take correctiveaction. It is generally desirable to stop the process 300 quickly insuch instances, to minimize waste and/or avoid the creation of defectiveproduct. The process 300 can be restarted once the broken web isrepaired. Additionally or alternatively, the control system can provideautomatic web tension and/or speed control. In preferredimplementations, for example, a drive speed of the rubber rollers 62 canbe matched or aligned with a drive speed in the laminator 94, to ensureconsistent speeds and/or tensions for the web materials. Likewise, thetension sensors 310 can monitor and/or control web tensions. Correctiveaction (e.g., a process stoppage) can be taken when web tension fallsoutside an acceptable range, for example, when a web has a loss oftension.

Additionally or alternatively, one or more sensors can be included tomonitor quantities of input and/or output materials. For example, one ormore sensors (e.g., length counters) can monitor the adhesive roll 54and/or the fabric roll 78 to determine when adhesive and/or fabricsupplies are running low. The process 300 can be stopped and new supplyrolls can be installed when a threshold limit is reached. Likewise, oneor more sensors (e.g., length counters) can monitor the first and secondrolls 126 and 132 to determine when a desired output volume (e.g., 150meters per roll) of the adhesive tape 10 has been reached. The first andsecond rolls 126 and 132 can then be removed and new output rolls of theadhesive tape 10 can be started, for example, on new cores. In certainexamples, a new adhesive roll 54 can be about 240 mm wide and containabout 300 meters of adhesive web material. Likewise, a new fabric roll78 can be about 470 mm wide and contain about 300 meters of fabric webmaterial. Other roll sizes can be used.

In some instances, the process 300 can provide a marking or some otherindication on the product materials to flag a portion of the adhesivetape 10 output as being defective. A marking system 316, for example,can add a mark (e.g., with ink or paint) to the fabric web 76 duringmachine startup or when other circumstances (e.g., a web break,misaligned webs, or poor lamination) result in defective product. Thiscan allow machine operators to more easily separate the defectiveproduct (e.g., an initial portion of the first and second rolls 126 and132) from the remaining product. Alternatively or additionally, theprocess 300 can utilize a sensor that detects the mark and automaticallydiverts bad product to a waste container.

Each numerical value presented herein, for example, in a table, a chart,or a graph, is contemplated to represent a minimum value or a maximumvalue in a range for a corresponding parameter. Accordingly, when addedto the claims, the numerical value provides express support for claimingthe range, which may lie above or below the numerical value, inaccordance with the teachings herein. Absent inclusion in the claims,each numerical value presented herein is not to be considered limitingin any regard.

The terms and expressions employed herein are used as terms andexpressions of description and not of limitation, and there is nointention, in the use of such terms and expressions, of excluding anyequivalents of the features shown and described or portions thereof. Inaddition, having described certain embodiments of the invention, it willbe apparent to those of ordinary skill in the art that other embodimentsincorporating the concepts disclosed herein may be used withoutdeparting from the spirit and scope of the invention. The features andfunctions of the various embodiments may be arranged in variouscombinations and permutations, and all are considered to be within thescope of the disclosed invention. Accordingly, the described embodimentsare to be considered in all respects as only illustrative and notrestrictive. Furthermore, the configurations, materials, and dimensionsdescribed herein are intended as illustrative and in no way limiting.Similarly, although physical explanations have been provided forexplanatory purposes, there is no intent to be bound by any particulartheory or mechanism, or to limit the claims in accordance therewith.

What is claimed is:
 1. A method comprising: providing a plurality ofadhesive webs, each adhesive web comprising a hot melt adhesive adheredto a backing material; providing a fabric web comprising a fabricmaterial; guiding a first adhesive web from the plurality of adhesivewebs into a first lateral location proximate a first side of the fabricweb; guiding a second adhesive web from the plurality of adhesive websinto a second lateral location proximate a second side of the fabricweb, wherein the second lateral location is different from the firstlateral location; applying heat and pressure to form a web of a baffletape comprising the first adhesive web bonded to the first side of thefabric web in the first lateral location and the second adhesive webbonded to the second side of the fabric web in the second laterallocation; and rewinding the web of the baffle tape into a roll.
 2. Themethod of claim 1, wherein providing the plurality of adhesive webscomprises unwinding at least one roll of adhesive material comprisingthe hot melt adhesive adhered to the backing material.
 3. The method ofclaim 1, wherein providing the plurality of adhesive webs comprisesslitting an initial adhesive web into the plurality of adhesive webs. 4.The method of claim 1, wherein providing the fabric web comprisesunwinding a roll of the fabric material.
 5. The method of claim 1,wherein providing the fabric web comprises slitting an initial fabricweb into a plurality of fabric webs comprising the fabric web.
 6. Themethod of claim 1, wherein guiding the first adhesive web comprisesdirecting the first adhesive web into the first lateral location, andguiding the second adhesive web comprises directing the second adhesiveweb into the second lateral location different from the first laterallocation.
 7. The method of claim 1, wherein guiding the first adhesiveweb comprises flipping the first adhesive web, such that the hot meltadhesive of the first adhesive web is positioned between the fabric weband the backing material of the first adhesive web.
 8. The method ofclaim 1, wherein the baffle tape comprises the first adhesive webpositioned proximate an edge of the fabric web and the second adhesiveweb positioned proximate an opposite edge of the fabric web.
 9. Themethod of claim 1, wherein the applying step comprises passing the firstadhesive web, the fabric web, and the second adhesive web through a nipof a belt lamination machine.
 10. The method of claim 1, furthercomprising: cutting the baffle tape into a plurality of adhesive strips;placing the plurality of adhesive strips in a predetermined arrangementbetween a first fabric sheet and a second fabric sheet; applying heatand pressure to (i) bond the plurality of adhesive strips to the firstfabric sheet and the second fabric sheet and (ii) form a plurality ofbaffles connecting the first fabric sheet and the second fabric sheet,wherein each baffle comprises a non-bonded portion of one of theplurality of adhesive strips.
 11. The method of claim 10, wherein thepredetermined arrangement comprises the plurality of adhesive strips ina substantially parallel and spaced-apart arrangement.
 12. The method ofclaim 10, wherein each adhesive strip from the plurality of adhesivestrips comprises a Z-shaped cross section.
 13. The method of claim 10,wherein the first and second fabric sheets and two adjacent bafflesdefine an insulation chamber.
 14. The method of claim 13, furthercomprising filling the insulation chamber with an insulating material.15. The method of claim 10, further comprising removing the backingmaterial from the plurality of adhesive strips prior to placing theplurality of adhesive strips in the predetermined arrangement.